Process of manufacturing metallic shapes



' c. A. WITTER. PROCESS OF MANUFACTURING METALLIC SHAPES. APPLICATION FILED OCT 4,1919.

11,348,677. PatentedAug 3,1920. 3 9 279 7 6 5 J 6 7 5 5 Ly) 2- {a 2- 2 \K k u rm\\\\\\\l l 4 cLf 1 a 1 V C 7 7 c. A. M PROCESS or MANUFACTURI ETALLIC SHAPES.

APPLICATION-FILED OCT 4,1919. 1,348,677, Patented Aug. 3, 1

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CLAUDE A. WITTEB, OF PHILADELPHIA, PENNSYLVANIA.

PROCESS OF MANUFACTURING METALLIC SHAPES.

Application filed. October 4,

To all whom it may concern Be it known that I, CLAUDE A. W ITTER, a citizen of the United States, residing in Philadelphia, Pennsylvania, have invented certain Improvements in Processes of Manufacturing Metallic Shapes, the same being a continuation in part of the subject matter of application Serial No. 286,889, of which the following is a specification.

One object of my invention is to improve the process of manufacturing rails and other shapes of iron and steel.

A further object of the invention is to manufacture a rail, or other shape, free of piping or other defects, usually due to iping.

A still further object of the invention is to provide a railroad rail with a high grade steel wearing surface and a comparatively low grade steel body, insuring strength and increasing the wearing qualities of the rail.

These objects I attain in the following manner, reference being had to the accompanying drawings, in which Figures 1 and 2, are sectional views showthe mold and ingot therein; Fig. 3, is a sectional view of a bloom forged to the required thickness and punched to remove the piping and'to suit either a becking hammer or a roughing mill;

Fig. 4, is a sectional view of a bloom as it comes from the becking hammer or the roughing mill;

Fig. 5, is a sectional view of a bloom which is shaped in a roughing'milhfor under a press, and which would have approximately the same cross section as the second pass of a'modern rail mill;

Fig. 6, is a blank finished, or partially finished, in cross section to form a rail;

Fig. 7, is a perspective view showing the endless ring shown inFig. 6 cut and ready to be straightened;

Fig. 8, is a side view showing a rail after passing through a straightening mill;

Fig. 9, is a sectional view of a bloom consisting of one grade of metal and punched to remove the piping; Y

Fig. 10, is a view showing the bloom after being shaped in a roughing mill, or under a press;

Fig. 11, is an endless ring of metal cut readyfor straightening; and

Figs. 12 to 17, inclusive, are sectional views of diflerent shapes which can be produced from the ring shown in Fig. 11.

Specification of Letters Patent.

Patented Aug. 3, 1920.

1919. Serial No. 328,454.

In the manufacture of railroad rails, bars,

and other shapes, the universal practice has been to roll the rail, or shape, directly from a bloom. The steel ingot from which the bloom is made has been cut to remove the ma or portion or all of the piping formed when pouring the ingot; this materially reduces the size of the ingot and, consequently, the size of the finished product. In some cases, where the piping is not entirely re moved, a flaw, due to the piping, often occurs at the most critical portion of the rail, or other shape.

By my invention, which I will now proceed to describe, I entirely remove the piping by punching so that the material left in the bloom formed from the ingot is of pure metal and any defects, due to piping, are entirely overcome and eliminated.

In Figs. 1 and 2, I have shown one form of ingot and the mold for making the same, but it will be understood that the ingots may be made in any form without departing from the essential features of the'invention.

In Figs. 1 and 2, I have shown an ingot having an outer portion of high grade steel and a comparatively low grade steel body.

It will be understood that an ingot of single metal may be used, depending upon the shape of the article to be produced and the use for which it is intended.

Referring to Figs. 1 and 2, 1 is the base of a mold and 2 is a section which may be made to form part of the base 1. 3 is a removable section. t is a brickset in the bottom of the mold. I11 the present instance, where it is desired to form the ingot of two grades of steel, I place a partition 5 in the mold; the partition being less in diameter than the mold so as to leave a space between the partition and the mold wall. This par tition is centered, in the present instance, by lugs 6 and is held in place by clamps 7. There are holes 8 in the upper portion of the partition to receive the hooks of a crane, when it is desired to remove the partition.

The low grade steel is poured into the center of the ingot mold, as at a, and the high grade steel is poured into the space between the partition andthe wall of the mold, as at b. The partition 5 is then withdrawn to allow the two metals to flow together, as illustrated in Fig. 2. The ingot thus formed is then reduced to a bloom by forging, as shown in Fig. 3, and a hole 0 of sufiicient diameter is punched out of the center of the ingot. This punching operation entirely removes the piping and also the 'segregations therefrom, and the body a,

of the bloom is of low grade steel, while the metal at the periphery is of high grade steel, as shown at b, Fig. 3. The bloom is:

then increased in diameter, as shown in Fig. 4:, by a becking hammer, or a roughing mill, 7, after which it may be shaped by continuing the operation to approximately the same cross sect on as one of thepasses of a modern rail or shape mill. By continuing V the operationthrough a roughing mill, or

by a press,-as illustrated in Fig. 5, the blank lsithen increased in dlameter by the beckmg process, as Well as reduced to a shape in cross section, which may be the final shape of the article to be produced, and when the desired diameter is reached the blank is cut, asat m, Fig. 7, after which it is passed through a straightening mill. so as to pro duce a straight rail, or other shape, of a given length, as shown in Fig. 8. It'will be understood that the blank may be brought to any desired degree of heat between the different steps of the process.

It will be understood, on referring to Figs. 3 to '7, both inclusive, that the high grade steelis at the wearing surface ofthe head of the rail, as at 6 whilethe steel 1 of lower grade forms the lower portion of thev head, the web, and the flange, as at a Fig. .6. i i I I In Figs. 3 to 7, both inclusive, I have shown a method in which the bloom is given approximately its final shape while in the circular form. 7

' In Figs.'.9 to 11, both inclusive, I have shown a bloom a of circular form, which has not been reduced to a particularform, but has been reduced to a blank, which may "be cut and straightened and then further 1 reduced and shaped in the ordinary rolling ing, process.

Figs. 14, 15-, 16, 17, show different shapes which may be made from a partially'shaped bloom bycontinuingthe OPGIZEUOII 1n a mill, or the shape may be entirely formed from a rectangular bloom, such as shown in Fig. 11.

' By the above described process, there are no losses other than the original punching, which removes the piping and, consequently, about 90% of the original ingot is in the finished product, whereas, in the ordinary process'of rolling, the finished product varies from to of the original ingot.

A further advantage is that the original which would not affect the wearing qualities thereof, nor would the strength of the rail be affected to any marked degree.

, It will be seen that when the ring is straightened the metal of the outer portion will, in the process of straightening, be compressed into a dense mass of greater strength and induration. This is particu larlyvaluable in the forming of railroad rails, for by this method a rail'is obtained in which the head or tread surface is greatly strengthened and improved in wearing qualities.

I claim:

1. The process herein described of manufacturingmetallic shapes, said process consisting in making an ingot, flattening the same and punching it to form a hole therein, then enlarging the bloom thus formed to form a ring, reducing the ring in cross section, then cutting the ring and straightening it. 7 r

2. The'process' herein described of manufacturing metallic shapes, said process consisting in making an ingot, flattening the same, removing the piping by punching a hole therein, then enlarging the bloom thus formed to form'a ring, then cutting the ring and straightening it. 7 r

Theprocess herein described of manufacturing railroad rails and other shapes, said process consisting in making an ingot, flattening the ingot and punching it to remove the piping and to form a hole therein, then enlarging the bloom thus formed, then shaping the bloom in cross section to the semblance of a rail, or like shape, then increasing the diameter of the blank thus formed and reducing it in cross section to the shape of the finished rail, then cutting the cylindrical blank and straightening it to form a rail, or like object.

4. The process herein described of manu facturing railroad rails, said process consisting in making an ingot having a comparatively low grade steel center and a high grade steel section at'the periphery, compressing the ingot to forma bloom with the high grade steel at the periphery, punching the ingot to remove the center and to form an opening for a becking tool, enlarging the opening in the bloom and shapingit in cross section to the rough shape of a rail, enlarging the blank thus formed, and then cutting the blank and straightening the same to produce a finished rail.

5. A method of manufacturing metallic shapes, comprising making a solid ingot, punching a hole therein and forming a ring, and straightening the ring to compress the outer portion of the same into a mass of greater density than the inner portion.

6. A method of manufacturing rails, comprising making an ingot, forming the same into a ring, shaping the ring to the form of the rail With the head at the outer portion of the ring, and straightening the ring to compress the head of the rail into a mass of greater density than the base of the rail.

CLAUDE A. WITTER. 

